Steel stud with openings and edge formations and method for making such a steel stud

ABSTRACT

A steel member ( 10,40,70,100 ) for use in supporting structures and having reduced heat transfer characteristics as compared with solid web studs, and having a web ( 12,42,72,102 ) defining side edges and an axis, a flange ( 14,44,74,104 ) on at least one side edge, openings ( 18,46,76,112 ) through said web ( 12,42,72,102 ) at spaced intervals therealong, of predetermined size and profile, at least a side portion of said web ( 12,42,72,102 ) removed from said opening ( 18,46,76,112 ) remaining attached integrally to said web ( 12,42,72,102 ), by bend lines being formed along axes parallel to said web axis.  
     Also disclosed is a composite member ( 130 ) made up of two such members ( 132 ) joined together.  
     Also disclosed is a method of making such a member ( 10,40,70,100,130,132 ).

FIELD OF THE INVENTION

The invention relates to steel studs or structural members formed withopenings, and with edge formations formed around the openings. Inparticular the studs are formed with edge formations along at least oneside of the openings, which are formed with at least two bends atrespective first and second angles with respect to the plane of thestud.

BACKGROUND OF THE INVENTION

Steel studs of a wide variety have been proposed for erectingstructures. Usually such studs are used to replace wooden studs. Wood isa relatively poor heat transfer medium. Heat losses through wooden studshas not been a significant problem in the past. Metal studs having solidwebs however, do create a heat loss transfer path through the wall orother structure. This results in cold patches along the lines of thestuds. Condensation, known as “ghosting” appears along these lines.

Such studs usually were formed as a C-section, ie there was a centralweb, and the opposite side edges of the web were formed into edgeflanges. Several such bends were sometime incorporated in an effort toget greater strength, while using thinner gauge metal. However this didnot overcome the heat transfer problem. Accordingly metal studs havebeen proposed with reduced heat transfer properties. These studs wereformed with generally triangular or trapezoidal openings, in the web,while the two edges were formed with bends, as before. These openingswere positioned so as to define diagonal struts extending across thestuds. Heat losses were thus reduced since there was less metal throughwhich the heat could pass. Also the heat transfer path was somewhatextended due to the diagonal placement of the struts. However when thesestuds are erected, it is usual for the builder to run services throughthe studs, within the wall. Where the openings in the metal studs are ofthese specialized generally triangular or trapezoidal shapes, theservices, in many cases conduits of substantial diameter, must be ableto fit through the openings.

It is not possible to the builder to cut away any of the diagonal strutsto provide larger openings for services, since this would drasticallyreduce the strength of the studs.

The shape of these openings tended to restrict the size of the conduitswhich could be passed through the studs.

Another problem arose in that the triangular openings were formed withedge flanges around their perimeter. Where these edge flanges extendedaround an angular corner of the opening there was a tendency for thesheet metal to crack. Consequently the corners had to be radiussed orrounded out. This meant that there was more metal at each of thecorners, than was desirable for heat transfer, and thermal losses couldoccur.

Another problem arose in cutting these studs to length. The openingswere arranged in pairs with one triangle facing one way and the nextfacing the opposite way. Cutting such studs to length requires that allof the openings of a particular orientation, in all of the adjacentstuds in a wall frame, shall line up. This required to facilitatepassing of services through the studs. However due to the alternatingorientation of the openings, this requirement resulted in cutting offend portions of studs equal in length to the space occupied by two ofthe stud openings, in many cases.

Concrete panels are also in wide use for attachment to the exterior ofstructures to provide for a wide variety of functional and aestheticeffects. Concrete panels are usually of relatively heavy thick materialof great weight. Great costs are involved in both materials, labortransportation, and erection of such heavy panels. Attachment of suchmassive panels to the exterior of a structure also presents seriousproblems. Proposals have been made for using panels of reducedthickness. Such panels are reinforced by a framework of metal studs.Usually the metal studs are partially embedded in the concrete. Theyprovide great strength to the panels, and also facilitate erection andattachment of the panels to the structure. Usually the inside surfacesof the resulting walls are covered in with wall sheeting, typicallyplaster wallboard. The sheeting is often attached directly to the metalstuds. The space between the concrete panels and the inner sheeting isusually insulated with suitable batts or the like. However it is knownthat the metal studs provide a heat transfer path which conducts heatfrom the building interior to the concrete panels on the exterior, andthere are thus substantial heat losses through the panels due to suchmetal studs. Accordingly it has been proposed to use the studs withopenings described above, with reduced heat transfer properties.

However there was another problem with such metal studs which arose incutting these studs to length. The openings in such metal studs werearranged in pairs with one triangle facing one way and the next facingthe opposite way. Construction methods require that all of the openingsof a particular orientation, in all of the adjacent studs in a wallframe, shall line up. This required to facilitate passing of servicesthrough the studs. However due to the alternating orientation of theopenings, this requirement resulted in cutting off end portions of studsequal in length to the space occupied by two openings, in many cases.This was waste metal and increased the cost of the building.

It has now been surprisingly found that the use of the specializedtriangular or trapezoidal shapes of these stud openings, is unnecessary.

Heat transfer reduction is possible, by the use of the invention, usingopenings with at least a portion of the opening being defined by asemi-circular radius. The remainder of the opening can be defined by anextended linear edge. In other embodiments the openings can be shapedwith four sides, as a quadrilateral.

This means that the size of the conduit passed through the openings canbe increased. The openings substantially span the distance across theweb, between the edge flanges of the stud. By the use of the inventionit is now possible to form openings which can accept conduits having adiameter equal to the distance across the web, between the edge flangesof the stud.

This is a great improvement over the earlier triangular openingconfiguration. Previously this was not thought to be possible sinceopenings with radiussed corners were thought to leave excessive metal inthe stud which would cause heat transfer losses. Similar advantages canalso be obtained in studs having openings of a quadrilateral shape. Inboth of these studs the openings are larger, and the struts runningdiagonally between the openings are at a greater angle, and being spacedfurther apart, than in studs previously known.

It has been found that by the use of relatively small additionalopenings, near each end of the diagonal struts, the actual heat transferpath can be so reduced, at critical points in the stud, so as tosubstantially improve on the heat transfer reduction achieved by the useof the specialized triangular or trapezoidal openings and diagonalstruts of earlier studs.

Semi-circular openings avoid the problems caused by the corners of thetriangular or trapezoidal openings and splitting of metal, and resultsin a much stronger stud. The use of semi-circular openings greatlyfacilitates high speed manufacture of such studs, since cutting tolength becomes less critical, and there is less stud length lost in theprocess.

The same is also true of studs having larger quadrilateral shapedopenings. This leads to further economies.

In both of these embodiments of studs the openings define servicepathways for cylindrical service conduits. In each stud the conduitdiameter can be equivalent to the distance across the stud between oneside edge of the opening and the other, transversely across the stud.This means that the conduits can pass through any opening in the stud,regardless of the orientation of the opening in the stud. This greatlyreduces wastage of sheet metal during manufacture.

Much larger conduits can be accepted.

Another factor is earlier designs was the thought that it was essentialto remove as much metal as possible, in order to reduce heat transferproblems.

It has now been found that this was incorrect. What is required is toleave a heat transfer path which is longer than a simple transverse linedirectly across the stud, and which has metal removed at selectedlocations so as to limit heat transfer.

It has also now been found that the linear edge of each opening can begreatly strengthened by removing less sheet metal at each opening,rather than more This surprising development results in leaving anadditional piece of sheet metal along side the linear edge. Thisadditional length can then be formed, in accordance with another aspectof the invention, into two generally angular bends, resulting in anadditional channel structure within the stud. Preferably both bends atright angular bends. This greatly increases the strength of the stud inthe critical area of the extended linear edge. The fact that more metalremains in the stud does not cause heat transfer problems, since theextra metal is in a location alongside the opening and thus where heatcannot be passed across the stud.

The blanks of sheet metal removed in this process, are of smaller sizethan was the case in previous triangular stud openings, notwithstandingthat the openings themselves are larger. This leads to economies in theprocess since the blanks are smaller. Slug ejection problems in themanufacturing machinery are reduced and there is less wastage of metal.

The semi-circular, or quadrilateral openings reduce the problems for thebuilder who wishes to pass service conduits through the studs within thewall. Much larger diameter pipes can now be fed through the studs, thanwas possible before. This leads to less sales resistance due to agreater acceptance of the product in the market place.

These features can be used in studs having edge formations for embedmentin concrete.

The features can also be used in forming much heavier duty studs withthe edge formations formed into a triangular tube shape.

Even stronger heavy duty studs can be formed by severing a single stripof sheet metal along a zig-zag parting line, so as to form two separatestrips of sheet metal. These two strips can be formed with formationsdescribed above and can then be joined together into a single compositestructural member.

One such a composite fabrication system is disclosed in U.S. Pat. No.5,207,045, inventor E R Bodnar, and in U.S. Pat. No. 5,592,848, inventorE R Bodnar.

However the composite members shown in those patents were difficult tofabricate, and their design shows what now appears to be structuralweaknesses at critical points, which would have reduced their loadbearing capacity. Such members were never in fact made, or used.

It will be appreciated that a stud which improves on all these problemsassociated with prior studs, will have application in general use, formany various construction applications. In particular however it willhave advantages in the reinforcement of thin-shell concrete panels.

BRIEF SUMMARY OF THE INVENTION

With a view to achieving the foregoing and other objectives theinvention comprises a steel member for use in supporting structures andhaving reduced heat transfer characteristics as compared with solid webstuds, and having a web defining side edges and an axis, a flange on atleast one side edge, openings through said web at spaced intervalstherealong, of predetermined size and profile, at least a side portionof said web removed from said opening remaining attached integrally tosaid web, a first bend formed in said side portion, a second bend formedin said side portion spaced from said first bend, said first and secondbends being formed along axes parallel to said web axis. The inventionfurther seeks to provide a steel member as described includingdepressions formed in said web at spaced intervals, and slots formed insaid depressions to reduce heat transfer.

The invention further seeks to provide a steel member as describedwherein said side portion defines a channel shape extending along anaxis parallel to said web axis.

The invention further seeks to provide a steel member as describedwherein said openings are of a shape defining a linear side edge, and anarcuate side edge, said side portion of said web being integral withsaid linear side edge

The invention further seeks to provide a steel member as describedwherein said openings have a first longer linear side, and a secondshorter linear side opposite to a parallel to one another.

The invention further seeks to provide a steel member as describedwherein said flanges are formed at an angle to said web and including aplanar wall extending from said flanges normal to said web, and lipsformed along said bracing walls, bent to form a channel shape.

The invention further seeks to provide a steel member as describedincluding side portions integrally formed of portions of said webremoved from said openings, and bent outwardly towards said lips of saidbracing walls, an edge of said side portions being captured in said lipswhereby to form generally triangular shaped tubes.

The invention further seeks to provide a steel member as describedwherein side portions are removed from the opening but remain integrallyattached to said web, said side portions, on one side of said web beingangled at an angle to said web diverging from said flanges, and anembedment lip formed along said side portions for embedment in aconcrete panel.

The invention further seeks to provide a steel member as describedwherein said flanges are formed at an angle to said web and including aplanar wall extending from said flanges normal to said web, and abracing wall extending integrally from said planar wall.

The invention further seeks to provide a steel member as describedincluding side portions formed by portions of sheet metal. removed fromsaid openings and remaining attached integrally to said web, said sideportions being interengaged with said bracing walls, to define agenerally triangular shaped tube extending along each side of saidmember.

The invention also provides a steel member for use in supportingstructures and having reduced heat transfer characteristics as comparedwith solid web studs, and having, a web defining a linear side edge anda zig zag side edge, and an axis, a flange on said linear side edge,openings through said web at spaced intervals therealong, ofpredetermined size and profile, at least a side portion of said webremoved from said opening remaining attached integrally to said web; afirst bend formed in said side portion, a second bend formed in saidside portion spaced from said first bend, said first and second bendsbeing formed along axes parallel to said web axis.

The invention also provides a composite member formed of two steelmembers as described being attached to one another to form a compositemember.

The invention also provides a method of making steel member having a weband side edges, and a flange along at least one said side edge, andopenings through said web, said method comprising the steps of, formingsaid openings in said web at spaced intervals therealong, with one sideof said opening leaving a side portion of metal attached to said web,forming said edge flange along said at least one side edge of said web,and, forming said side portion out of the plane of said web by bendingsaid side portion along a first bend line and then along a second bendline spaced from said first bend line.

The various features of novelty which characterize the invention arepointed out with more particularity in the claims annexed to and forminga part of this disclosure. For a better understanding of the invention,its operating advantages and specific objects attained by its use,reference should be made to the accompanying drawings and descriptivematter in which there are illustrated and described preferredembodiments of the invention.

IN THE DRAWINGS

FIG. 1 is a perspective illustration of a stud illustrating oneembodiment of the invention, in which the openings have one side edgewhich is semi-circular;

FIG. 2 is a side elevation of the stud of FIG. 1;

FIG. 3 is a section along line 3-3 of FIG. 2;

FIG. 4 is a view of a detail of FIG. 2 shown at circle 4;

FIG. 5 is a section along line 5-5 of FIG. 2;

FIG. 6 is a section along line 6-6 of FIG. 4;

FIG. 7 is a section along line 7-7 of FIG. 2;

FIG. 8 is a perspective of a further embodiment of stud illustratinganother embodiment of the invention, in which the openings are ofgenerally quadrilateral shape;

FIG. 9 is a perspective of a portion of FIG. 8 from another angle;

FIG. 10 is a side elevation of the stud of FIG. 8;

FIG. 11 is a section along line 11-11 of FIG. 10

FIG. 12 is a perspective of a further embodiment of stud for use inreinforcing concrete panels;

FIG. 13 is a side elevation of the stud of FIG. 12;

FIG. 14 is a section of the stud of FIG. 13

FIG. 15 is a perspective of a stud having some features similar to FIG.1 and some features similar to FIG. 8;

FIG. 16 is a perspective of a further embodiment of stud for use inmaking a composite member;

FIG. 17 is a side elevation of the stud of FIG. 16;

FIG. 18 is an enlarged section along line 18-18 of FIG. 17;

FIG. 19 is a perspective of a composite member formed of two of the FIG.16 studs joined together;

FIG. 20 is a perspective of a further embodiment employing depressionswith round holes through them;

FIG. 21 is a side elevation of the embodiment of FIG. 20;

FIG. 22 is a side elevation of a stud for embedment in a concrete panel,and,

FIG. 23 is an end elevation of the stud of FIG. 22.

DESCRIPTION OF A SPECIFIC EMBODIMENT

As already described the invention provides sheet metal studs, havingreduced thermal conductivity, suitable for use in erecting variousstructures, walls, floors, roofs, and the like. The invention alsoprovides sheet metal studs suitable for use in reinforcement ofthin-shell concrete panels which are widely used in completing walls, inparticular. Such thin-shell structures can also form floors, roofs andthe like. The invention also provides composite members formed byjoining two stud portions together, and a method of making such acomposite member.

Referring to FIG. 1 it will be seen that the invention is thereillustrated in the form of a stud (10), formed of sheet metal, in thiscase steel. The stud (10) has a web (12) which is essentially planar,and edge flanges (14) along each side edge of the web (12). Each of theflanges is formed by bending the web at right angles. Lips (16) areformed on each edge flange ( ) again at right angles.

In the web (12) openings (18) are formed by punching out a portion ofthe sheet metal.

In this embodiment the openings (18) are formed with a semi-circular orarcuate profile on one side as at (20). On the opposite side theopenings (18) are formed with an elongated linear profile side as at(22). Between the arcuate profile (20) and the linear profile (22) thereare shorter linear junctions. Between the linear profile and thejunction as there are radiussed corners as at (24). Extending all aroundopening (18) there is an edge rim flange (26) formed at right angles tothe web (12). Along the linear side profile (22) of the opening there isa bracing lip (28) formed. Lip (28) is formed by a portion of the web(12) which is has been partly punched out but which remains joinedthereto along such side of the opening (18). Bracing lip (28) is formedat a first right angle (30) normal to the plane of the web, and then itis formed at a second right angle (32) parallel to but spaced from theplane of the web (12).

In this way bracing lip (28) forms a short channel shape, extendingalong the linear side of the opening (18). In this way lip (28) greatlyreinforces the stud (10) along the length of the linear side of opening(18).

This feature permits the openings (18) to be formed with relativelylarge dimensions, so that a conduit, shown in phantom as C, can extendthrough opening (18) and is limited only by the transverse dimension ofthe opening transversely across the web (12). This is a greatimprovement over studs having triangular openings. In such triangularopenings conduit size is severely restricted, by the geometry of theopening, or in the alternative was capable of accepting only flexibleround air handling ducts.

It will be noted that the shape and placement of the openings (18)defines struts (34) extending diagonally across the web (12). Suchstruts are longer than the struts defined in studs having triangularopenings, and are thus longer. Since heat, by conduction, can pass onlyalong such struts, the actual heat loss due to the struts is less thanin a comparable stud with triangular opening. Studs (10) are furtherformed with depressions (36) at opposite ends of each strut (34) wherethe strut flares out into the web (12). Centered across depression (36)there are punched out slots (38). The slots (38) provide an effectivebarrier to conduction of heat across the stud and improve its thermalefficiency. Heat, by conduction, will have to travel of a winding pathbefore reaching the edge of the stud at the outside wall (not shown).This embodiment of stud is particularly advantageous. It combines thegreat strength of the triangular tubes on both edges of the stud, andalso the retention of the greatest amount of metal removed by blankingthe openings. The largest part of such metal is retained and is foldedover outwardly to form bracing walls forming one side of the tube. FIGS.8 to 11 illustrate another embodiment of stud (40). This stud has somefeatures which are common to stud (10) of FIG. 1. Thus it has a web (42)and edge flanges (44).

However the edge flanges (44) are bent out of the plane of the web byabout 45 degrees for reasons to be described. The angle can varysomewhat for various applications.

In this case the stud (40) has openings (46) which are of generallyquadrilateral shape.

Openings (46) have a long linear side (48) and a short linear side (50)parallel to one another. Two diagonal sides extend between long side(48) and short side (50). Where two adjacent diagonal sides meet thelong side (48) there are radiussed corners.

Where the two adjacent diagonal sides meet the short side (50) there areangular corners. The diagonal sides of two adjacent openings (46) definebetween them struts (52), which extend from one side to the other of theweb (42), along diagonal paths.

The stud (40) could be formed with lips on the edge flanges as inFIG. 1. However in this case the stud is intended for a heavier dutyapplication. The edge flanges (44) are thus formed with extended clampchannel lips(54).

The metal of the web (42) punched out from the opening (46) is notcompletely severed in this case. Bracing plates (56) and (58) extend asintegral portions of web (42) along longer side (48) and along shorterside (50) of the opening. Plates (56) and (58) are folded back atsubstantially 45 degrees, an angle which will be equal and opposite tothe angle of edge flange (44). The free edges of bracing plates (56) and(58) are turned over and interfitted in channels (54) of flanges (44),thus forming a series of discontinuous lengths of tube of generallytriangular configuration in section, extending along the axis of eachside of the strut (40).

The bracing plates (56) and (58) are formed with a series ofindentations (60) for greater strength.

In order to reduce heat transfer, are series of depressions (62) areformed in edge flanges (44) adjacent each end of each strut (52), andslots (64) are formed in the depressions, as in FIG. 1.

Many features of the studs of FIGS. 1 and or 5, are also adaptable toforming a stud for use in reinforcing thin shell concrete panelconstruction.

Such a stud (70) is shown in FIGS. 12, 13, and, 14.

Stud (70) has a web (72), and angled edge flanges (74) as in FIG. 5.Stud (70) has openings (76) of quadrilateral shape as in FIG. 5.

Along one side of web (72) there are a series of bracing plates (78) asin FIG. 5. These bracing plates (78) are bent at an angle. Free edges ofplates (78) are captured in channel (80) formed on the edge flanges(74), thus forming a series on lengths of tube. Both the edge flangesand the bracing plates are formed with linear indentations for greaterstrength.

On the opposite side edge of the web (72) there are modified edgeflanges (82), and modified bracing plates (84). Flanges (82) are bentoutwardly, and are formed with a series of openings or ports (86) forconcrete flow.

A return lip (88) is formed along flange (82) for embedment in concreteBracing plates (84) being formed by integral portions of web (72) struckout of openings (76) are folded back at an angle to complement flanges(82) and are discontinuous. Embedment lips (90) are formed on plates(84) for embedment in concrete.

Thus this embodiment provides a stud of great strength providingreinforcement for a concrete panel. The flanges (82) and the plates (84)being partially embedded in concrete but being spaced laterally apart inthe panel will provide maximum security of adhesion between the studsand the concrete.

This stud enables the use of a reduction in thickness of sheet metal. Itis anticipated that a reduction of at least one gauge and probably twogauges can be achieved while still providing adequate support to aconcrete panel.

This will reduce the cost of the panels. It will also reduce the heattransfer through the panel and stud, since the reduction in gaugereduces the actual mass of metal available to provide a heat transferpath.

FIG. 15 shows a further form of stud (100) having features still furtherincreasing its strength, or, conversely, permitting the use of a thinnergauge material and still achieving the same or better strength ascompared with earlier studs.

Stud (100) has a web (102) and identical edge flanges (104) along eitherside of the web. Flanges (104) are bent at an angle to the plane of theweb. Integral planar walls (106) extend from flanges (104) normal to theplane of the web. Bracing walls (108) extend integrally from walls (106)and are bent inwardly complementary to the angle of flanges (104). Walls(106) terminate in angled lips (110) which contact and lie against theweb (102). Lips (110) are bent into an L-shape and extend normal to theplane of the web (102). Openings (112) are formed through web (102) asbefore, being of quadrilateral shape as in the FIG. 8 embodiment, andhaving edge rims or flanges (114) formed therearound as before. Linearside edges (116) and (118) of opening (112) are defined by flaps (120)of sheet metal, extending integrally from flanges (114) for purposes tobe described, thus retaining more of the metal removed by the opening(112) and employing it to improve the stud, rather than discarding it aswaste. Flaps (120) are folded back on themselves to capture adjacentlips (110) on walls (108). Thus each side of the stud is formed with acontinuous triangular tube for great strength, and the free edge of eachtube is captured and held, at intervals, by integral flaps struck outfrom the openings. More metal. is retained in the stud, which bothincreases its strength, or in the alternative permits a reduction ingauge, without in any way increasing the heat losses through the stud.Ridges are formed in flanges (104) and walls (108) for greater strength.Depressions, and slotted openings (not shown) may be formed in the web,as described above to further reduce heat losses. Tis form of staud mayhave even greater strength than the FIG. 5 stud in certaincircumstances. However it will be seen that it does require the use of awider web initially. The bracing walls are formed integrally with theedge flanges and planar walls. This means that it will require a widerstrip to start with to have sufficient metal to form these walls.Conversely this embodiment retains somewhat less of the metal blankedout from the opening, and is therefor somewhat more wasteful.

A further embodiment of stud is shown in FIGS., 16 17, 18, and 19.

This is a composite member (130) made up of two studs (132) which areformed separately from one another, and are then joined together (FIG.19) to provide the composite member (130) of great strength and lightweight.

In this embodiment two studs (132) are formed each having identicalcomponents.

The two studs may be formed by parting a single strip of sheet metal, orcan simply be formed as a single strip having a straight edge and azig-zag edge, and then cut into two identical lengths.

Each stud (132) has a web (134). One side edge of the web is straight.It has a continuous edge flange (136) bent at an angle to web (134) asin FIG. 10.

A planar tube wall (138) extends from flange (136). The free edge ofwall (138) is turned back at an angle complementary to flange 1360 toprovide a ridged wall (140). The flange (136) wall (138) and wall (140)together form a triangular cross-section tube axially along one side ofthe web which greatly reinforces the stud.

Ridges (142) are formed in flange (136) and in wall (140) for greaterstrength. Web (134) is formed with openings (144) which have base linearside (146) and an arcuate side (148) opposite to side (146). Edge rimsor flanges (150) are formed around openings (144)

Some metal alongside base edge (146) is left intact and is folded overto form fold channels (152) to capture the free edge of wall (140) atintervals. Between folds (152) there are depressions (154) formed in web(134) and in wall (140) to assist in restricting movement.

The side edge of web (134) opposite to flange (136) is formed along azig-zag path defining peaks (156) and valleys (158). Along the zig-zagedge there is an edge flange (160) formed continuously.

In use two such studs (132) are juxtaposed as shown in FIG. 19 withtheir peaks (156) touching, and their valleys defining large, generallyhexagonal openings through the member. Large diameter conduits can thusbe passed through the member as desired. Peaks (156) are secured to eachother as by welding or the like to form a composite member.

Manufacture of the studs (10) of FIG. 1 can proceed by first forming theopenings (18) and rim flanges (26) in a suitable press. This can be aflying die press, but it is advantageous to use a rotary press of thetype which has two rotary die support rolls, and dies on the supportrolls, in which the two support rolls rotate bringing the dies togetherand apart as the sheet metal moves between them. After blanking andforming of the openings and forming of the edge flanges around theopenings, and the forming of the depressions (36) and punching of theslots (38) where used, the semi-formed sheet metal is then passedthrough a series of roller die stands, such as are known per se andrequire no description. The roller dies on the die stands willprogressively form the edge flanges (14) and the axial bends (30) and(32) in the flanges (14) on either side of the openings.

In FIG. 8, and in FIG. 13 and in FIG. 15, where the lips are to beturned over to capture the plates, this too is performed in a series ofroller dies through which the sheet metal. passes at high speed, and isformed and bent along the axis of the sheet metal in an efficient andeconomical manner.

Cutting to length will normally be performed upstream of the rotarypress where the strip sheet is still flat and unformed. In this way eachpiece of sheet metal passing through the various punching and formingand roll forming sequences is already precut to the exact lengthrequired for the finished stud.

It also possible to cut to length downstream of the roller dies,although this may be difficult to control.

It must be remembered that in cutting to length, provision must be leftat each end of each stud to leave end portions of the stud free ofopenings, so that in can be stood in place in an eventual structure,with all of the openings in each stud aligned with one another acrossthe structure. This will greatly facilitate the installation of servicesthrough the openings.

Suitable controls which form no part of the invention are incorporatedin the rotary press so that the rotary press is timed to operate exactlywhere required on each stud. Where openings and forming are notrequired, at each end of each stud, the controls disable the rotarypress so that leading and trailing ends of the sheet metal pass throughunpunched and unformed.

In the case of the FIG. 19 embodiment, after forming the two studs(132), their peaks (156) are secured together as by welding or any othersuitable fastening, to form the composite member (130).

FIGS. 20 and 21 show a further embodiment. In this case stud (170) Issimilar to the studs of FIG. 1 having a web (172) and flanges (174).

Openings (176) through web (172) are of generally quadrilateral shape,similar to the openings (46) of FIG. 10. Channels (178) are formed as inFIG. 1.

Depressions (180) with central round holes (182) are formed in web (172)located in the same place as depressions (36) of FIG. 1. The round holesare found to restrict heat transfer through the web. By forming theround holes as depressions they are formed with edge flanges as shownand they thus add to the strength of the stud.

This feature of round holes and edge flanges can be used in place of thedepressions shown in the other figs, including (36) or (62) or (154).

FIGS. 22 and 23 show a stud for embedment in a concrete panel.

The stud (190) is similar in most respects to the stud of FIG. 1, andhas most of the same features. The stud (190) may have semi radiussedmain openings as in FIG. 1 or may have trapezoidal main openings as inFIGS. 10 and 20.

The stud (190) has round holes (192) as in the embodiment of FIGS. 20and 21. In this case however one edge flange (194) is bent outwardly toform angled flange(196). Angled flange (196) is formed with slot likeopenings (198) for flow of concrete therethrough. A locking strip (200)is bent over along the free edge of angled flange (196).

This form of angled flange for embedment in concrete can be adapted toeither the FIG. 1 stud or the FIG. 10 stud or other variations ofeither. The foregoing is a description of a preferred embodiment of theinvention which is given here by way of example only. The invention isnot to be taken as limited to any of the specific features as described,but comprehends all such variations thereof as come within the scope ofthe appended claims.

1. A steel member (10,40,70,100) for use in supporting structures andhaving reduced heat transfer characteristics as compared with solid webstuds, and characterized by: a web (12,42,72,102,172) defining sideedges and an axis; a flange (14,44,74,104) on at least one side edge;openings (18,46,76,112) through said web (12,42,72,102) at spacedintervals therealong, of predetermined size and profile, at least a sideportion (32, 58, 78,84,120, 152) of said web (12,42,102,170) beingremoved from said opening (18,46,76,112) and remaining attachedintegrally to said web (12,42,72,102,172), and being bent away from saidweb (12,42,72,102, 172) along axes parallel to said web axis.
 2. A steelmember (10,40) as claimed in claim 1 including depressions (36,62, 182)formed in said web (12,42) at spaced intervals, and openings (38,64,184)) formed in said depressions (36,62, 182) to reduce heat transfer.3. A steel member (10,40,70,100,170) as claimed in claim 1, wherein saidside portion defines a channel shape extending along an axis parallel tosaid web axis.
 4. A steel member (10) as claimed in claim 1 wherein saidopenings (18) are of a shape defining a linear side edge (22), and anarcuate side edge (20), said side portion (32) of said web (12) beingintegral with said linear side edge (22).
 5. A steel member (10) asclaimed in claim 1 wherein there are two said flanges (14) one on eachside of said web (12), being formed at normal to said web (12), and lips(16) formed along said flanges (14), normal to said flanges (14).
 6. Asteel member (10,40,70,100,170) as claimed in claim 1 said openings(18,46,76,112) are arranged in an alternating orientation and definebetween them struts (34,52,) extending diagonally across said member(10,40,70,100,170).
 7. A steel member (10,40,70,100,170) as claimed inclaim 6 including openings (38,64, 182) formed in said web(12,42,72,102,172) at opposite ends of each said strut to restrict heattransfer through said member.
 8. A steel member (40,70,100) as claimedin claim 1 wherein said openings (46,76,112) have a first longer linearside (48,116), and a second shorter linear side (50,118) opposite to andparallel to one another.
 9. A steel member (40,70,100) as claimed inclaim 8 including diagonal sides extending between said linear sides,defining a generally quadrilateral shape.
 10. A steel member (40,70,100)as claimed in claim 9 wherein said openings (46,76,112) are arranged inan alternating orientation, and wherein said diagonal sides definestruts therebetween extending across said member (40,70,100).
 11. Asteel member (10,40) as claimed in claim 9 including slots (38,64)formed in said web (12,42) adjacent the ends of each said strut (34,52)whereby to restrict heat transfer.
 12. A steel member (40,70,100) asclaimed in claim 10 wherein said flanges (44,74,104) are formed at anangle to said web (42,72,102) and including a planar wall (106)extending from said flanges (44,74,104) normal to said web (42,72,102),a bracing wall (108) formed on said planar wall and lips (54,80,110)formed along said bracing wall bent to form a channel shape.
 13. A steelmember (100) as claimed in claim 12 including side portions integrallyformed of portions of said web (102) removed from said openings (112),and bent outwardly towards said lips (110) of said bracing walls (108),an edge of said side portions being captured in said lips (110) wherebyto form generally triangular shaped tubes.
 14. A steel member (10,40) asclaimed in claim 13 including openings (38,64) formed in said web(12,42) along said flanges (14,44) to reduce heat transfer.
 15. A steelmember (70) as claimed in claim 12 wherein side portions are removedfrom the opening (76) but remain integrally attached to said web (72),said side portions, on one side of said web (72) being angled at anangle to said web (72) diverging from said flanges (82), and anembedment lip (88) formed along said side portions for embedment in aconcrete panel.
 16. A steel member (70) as claimed in claim 15 includinga further embedment lip (90) formed on said flange (84) on said one sideof said web (72), whereby to provide further embedment in a saidconcrete panel.
 17. A steel member (100) as claimed in claim 10 whereinsaid flanges (104) are formed at an angle to said web (102) andincluding a planar wall (106) extending from said flanges (104) normalto said web (102), and a bracing wall (108) extending integrally fromsaid planar wall (106).
 18. A steel member (100) as claimed in claim 17including side portions formed by portions of sheet metal removed fromsaid openings (112) and remaining attached integrally to said web (102),said side portions being interengaged with said bracing walls (108), todefine a generally triangular shaped tube extending along each side ofsaid member (100).
 19. A steel member (100) as claimed in claim 18wherein said bracing walls (108) extend from said planar walls (106) atan angle complementary to said flanges (104), whereby said bracing walls(108) lie against said web (102) at their edge, and capture lips (110)bent outwardly from said bracing walls, and captured in said sideportions.
 20. A steel member (100) as claimed in claim 19 wherein saidside portions along said longer linear sides (116) are longer, andwherein said side portions along said shorter linear sides (118) areshorter, and wherein said bracing walls (108) and said lips (110) onsaid walls (108), extend continuously along the web (10) parallel to theaxis of the web (102).
 21. A steel member (132) as claimed in claim 1wherein said web (134) defines a linear side edge (146) and a zig zagside edge (156,158), and a web axis; a flange (136) on linear side edge(146); openings (144) through said web (134) at spaced intervalstherealong, of predetermined size and profile, at least a side portionof said web (134) removed from said opening (144) remaining attachedintegrally to said web (134); and defining bends being formed along axesparallel to said web axis.
 22. A steel member (132) as claimed in claim21 wherein said flange (136) connects with a planar wall (138) normal tosaid web (134), and including a bracing wall (140) integral with saidplanar wall (138) and bent at an angle complementary to said flange(136).
 23. A steel member (132) as claimed in claim 22 including a foldportion (146) engaging said bracing wall (140)
 24. A composite member(130) formed of two steel members (132) as claimed in claim 21, said twomembers (132) being attached to one another to form a composite member(130).
 25. A steel member (132) as claimed in claim 24 wherein said zigzag edge (156,158) defines peaks (156) and valleys (158) and whereinsaid two members (132) are connected at their peaks (156) and aresecured to one another at said peaks (156), said valleys (158) in saidtwo members (132) registering with one another and defining openingsthrough said composite member (130).
 26. A method of making steel member(10,40,70,100,132) having a web (12,42,72,102,134) and side edges, and aflange (14,44,74,104,136) along at least one said side edge, andopenings (18,46,76,112,144) through said web (12,42,72,102,134), saidmethod characterized by the steps of; forming said openings(14,44,74,104,136) in said web (12,42,72,102,134) at spaced intervalstherealong, with one side of said opening (14,44,74,104,136) leaving aside portion of metal attached to said web (12,42,72,102,134); formingsaid edge flange (14,44,74,104,136) along said at least one side edge ofsaid web (12,42,72,102,134), and, forming said side portion out of theplane of said web (12,42,72,102,134) by bending said side portion alongbend lines parallel to the web axis.
 27. A method of making steel member(100) as claimed in claim 26 and including the step of forming a planarwall (106) on said flange (104) normal to said web (102), forming acapture lip (110) on said planar wall (106), and, bending said sideportion over said capture lip (110).
 28. A method of making steel member(10) as claimed in claim 26 and including the step of forming struts(34) extending across said web (12) between said openings (18) andforming slots (38) in said web (12) adjacent each end of each strut(34).
 29. A method of making steel member (40,70,100) as claimed inclaim 26 and including the steps of forming openings (46,76,112) in saidweb (42,72,102) of generally quadrilateral shape and defining a longerlinear side (48,116) and a shorter linear side (50,118), and said sideportions of said web (42,72,102) remaining attached thereto andextending integrally from said first and said second linear side(48,50,116,118).
 30. A method of making steel member (40,70,100) asclaimed in claim 29 and including the steps of forming both said sideportions over portions of adjacent flanges (44,74,104).
 31. A method ofmaking steel member (40,70,100) as claimed in claim 29 and including thesteps of forming said side portions at an angle to said web (42,72,102)diverging from said flanges (44,74,104), and capturing an edge of eachside portion in portions of said flanges (44,74,104).
 32. A method ofmaking steel member (132) as claimed in claim 26 wherein one side edge(146) of said web (134) is linear and the other side edge (156,158) iszig zag.
 33. A method of making steel member (132) as claimed in claim32 and including the steps of forming said at least one edge flange(136) along said linear side edge (146), and forming rim flanges (160)along said zig zag edge (156,158), and forming openings (144) throughsaid web (134).
 34. A method of making steel member (132) as claimed inclaim 32 and including the steps of forming side portions of said web(134) remaining attached thereto and bending said side portions out ofthe plane of said web (134), and folding said side portions aroundportions of said edge flanges (136) on said linear side (146) of saidweb (134).
 35. A method of making steel member (132) as claimed in claim26 wherein said zig zag edge (156,158) defines peaks (156) and valleys(158), and including the step of joining two said members (132) togetherwith their peaks (156) in contact with one another to form a compositemember (130).
 36. A steel stud as claimed in claim 1 for embedment inconcrete and including an angled flange (196) formed with openings (198)for flow of concrete therethrough, and a locking strip (200) formedalong said angled flange.